Thermal stress analysis of epoxy encapsulants.
Thermal stress analysis of epoxy encapsulants using mathematical model for predicting performance in thermal shock
EPOXY RESIN↗
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THERMAL STRESS ANALYSIS OF A SPENT NUCLEAR FUEL CANISTER
The potential for chloride induced stress corrosion cracking (CISCC) in spent nuclear fuel dry storage canisters is a current topic of research by the US Department of Energy Spent Fuel and Waste Science and Technology program. One of the important prerequisites for CISCC is a tensile residual stress state. This study utilizes computational models to provide an initial analysis of thermal stresses in a generic spent nuclear fuel canister. A STAR-CCM+ thermal fluid model provides a temperature profile analysis of the canister based on four different ambient temperature conditions. An ANSYS APDL finite element model incorporates the temperature profiles to analyze the thermal stresses in the canister. The calculated thermal stress magnitudes are in the range of 10 MPa to 80 MPa, which could be significant for crack propagation through the canister wall. The maximum thermal stress is not a concern for the structural failure of the canister, but it is high enough that it is a significant contribution to the total stress state of the canister wall, which also includes residual stress from fabrication, internal pressure from helium cover gas, and potential transient mechanical loads, such as earthquakes. This paper describes the initial finite element thermal stress analysis that was completed in 2020, reports the initial findings, and identifies areas where model refinement is still needed to complete this work in the future.
Jensen, Ben J.↗
A comparison of measured and calculated thermal stresses in a hybrid metal matrix composite spar cap element
A hybrid spar of titanium with an integrally brazed composite, consisting of an aluminum matrix reinforced with boron-carbide-coated fibers, was heated in an oven and the resulting thermal stresses were measured. Uniform heating of the spar in an oven resulted in thermal stresses arising from the effects of dissimilar materials and anisotropy of the metal matrix composite. Thermal stresses were calculated from a finite element structural model using anisotropic material properties deduced from constituent properties and rules of mixtures. Comparisons of calculated thermal stresses with measured thermal stresses on the spar are presented. It was shown that failure to account for anisotropy in the metal matrix composite elements would result in large errors in correlating measured and calculated thermal stresses. It was concluded that very strong material characterization efforts are required to predict accurate thermal stresses in anisotropic composite structures.
Jenkins, J. M.↗
Boundary layer thermal stresses in angle-ply composite laminates, part 1
Thermal boundary-layer stresses (near free edges) and displacements were determined by a an eigenfunction expansion technique and the establishment of an appropriate particular solution. Current solutions in the region away from the singular domain (free edge) are found to be excellent agreement with existing approximate numerical results. As the edge is approached, the singular term controls the near field behavior of the boundary layer. Results are presented for cases of various angle-ply graphite/epoxy laminates with (theta/-theta/theta/theta) configurations. These results show high interlaminar (through-the-thickness) stresses. Thermal boundary-layer thicknesses of different composite systems are determined by examining the strain energy density distribution in composites. It is shown that the boundary-layer thickness depends on the degree of anisotropy of each individual lamina, thermomechanical properties of each ply, and the relative thickness of adjacent layers. The interlaminar thermal stresses are compressive with increasing temperature. The corresponding residual stresses are tensile and may enhance interply delaminations.
Wang, S. S.↗
CODE-TO-CODE BENCHMARK STUDY FOR THERMAL STRESS MODELING AND PRELIMINARY ANALYSIS OF THE HIGH-TEMPERATURE SINGLE HEAT PIPE EXPERIMENT
Microreactors are very small nuclear reactors with typical thermal-energy output of up to 20 MWth. The microreactor concept is gaining more and more attention for safe, robust, and reliable supply of electricity for remote locations and to meet industrial process heat needs. Heat-pipe-cooled microreactor is one of the microreactors being investigated at Idaho National Laboratory. In the heat-pipe-cooled microreactor, heat pipes remove heat from the reactor core as a passive heat-transfer device, so the fluid circulation is not required for cooling, which can substantially simplify the overall reactor design. However, given the extremely high temperatures in the core region and potentially large temperature gradients across the structure materials, thermal stresses need to be well-analyzed to ensure structural integrity during normal operations and accident scenarios for the heat-pipe-cooled microreactor designs. This paper discusses finite element method-based thermal-stress analysis for the high-temperature single heat-pipe test article in the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory, using two commercial software packages, Abaqus and STAR-CCM+. A code-to-code benchmark study was performed to crosscheck the model setup and capability of each code and to gain insights into the potential thermal stress concerns from the current experimental setup. It is observed the significant thermal stresses happen at the locations where the largest temperature gradients appeared between heat pipe and electric heater. The temperature fields have good agreements between Abaqus and STAR-CCM+, while the induced thermal stresses show modest deviations probably due to differences of meshing engines used in these two codes.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Transient thermal stress problem for a circumferentially cracked hollow cylinder
The paper is concerned with the transient thermal stress problem for a long hollow circular cylinder containing an internal axisymmetric circumferential edge crack that is suddenly cooled from inside. It is assumed that the transient thermal stress problem is quasi-static, i.e., the inertial effects are negligible. Also, all thermoelastic coupling effects and the possible temperature dependence of the thermoelastic constants are neglected. The problem is considered in two parts. The first part is the evaluation of transient thermal stresses in an uncracked cylinder; the second part is the isothermal perturbation problem for the cracked cylinder in which the crack surface tractions, equal and opposite to the thermal stresses obtained from the first problem, are the only external loads. The superposition of the two solutions gives results for the cracked cylinder.
Nied, H. F.↗
Thermal stress and low-cycle fatigue.
Text on thermal stress and low-cycle fatigue covering elastic stresses, plastic flow and creep, stress cycling, etc
THERMAL STRESS↗
Correlation of predicted and measured thermal stresses on an advanced aircraft structure with dissimilar materials
Additional information was added to a growing data base from which estimates of finite element model complexities can be made with respect to thermal stress analysis. The manner in which temperatures were smeared to the finite element grid points was examined from the point of view of the impact on thermal stress calculations. The general comparison of calculated and measured thermal stresses is guite good and there is little doubt that the finite element approach provided by NASTRAN results in correct thermal stress calculations. Discrepancies did exist between measured and calculated values in the skin and the skin/frame junctures. The problems with predicting skin thermal stress were attributed to inadequate temperature inputs to the structural model rather than modeling insufficiencies. The discrepancies occurring at the skin/frame juncture were most likely due to insufficient modeling elements rather than temperature problems.
Jenkins, J. M.↗
Thermal stress analysis of symmetric shells subjected to asymmetric thermal loads
The performance of the NASTRAN level 16.0 axisymmetric solid elements when subjected to both symmetric and asymmetric thermal loading was investigated. A ceramic radome was modeled using both the CTRAPRG and the CTRAPAX elements. The thermal loading applied contained severe gradients through the thickness of the shell. Both elements were found to be more sensitive to the effect of the thermal gradient than to the aspect ratio of the elements. Analysis using the CTRAPAX element predicted much higher thermal stresses than the analysis using the CTRAPRG element, prompting studies of models for which theoretical solutions could be calculated. It was found that the CTRAPRG element solutions were satisfactory, but that the CTRAPAX element was very geometry dependent. This element produced erroneous results if the geometry was allowed to vary from a rectangular cross-section. The most satisfactory solution found for this type of problem was to model a small segment of a symmetric structure with isoparametric solid elements and apply the cyclic symmetry option in NASTRAN.
Negaard, G. R.↗
Thermal stress analysis of space shuttle orbiter subjected to reentry aerodynamic heating
A structural performance and resizing (SPAR) finite-element computer program and NASA structural analysis (NASTRAN) finite-element computer programs were used in the thermal stress analysis of the space shuttle orbiter subjected to reentry aerodynamic heating. A SPAR structural model was set up for the entire left wing of the orbiter, and NASTRAN structural models were set up for: (1) a wing segment located at midspan of the orbiter left wing, and (2) a fuselage segment located at midfuselage. The thermal stress distributions in the orbiter structure were obtained and the critical high thermal stress regions were identified. It was found that the thermal stresses induced in the orbiter structure during reentry were relatively low. The thermal stress predictions from the whole wing model were considered to be more accurate than those from the wing segment model because the former accounts for temperature and stress effects throughout the entire wing.
Ko, William L.↗
Thermal stress fracture in elastic-brittle materials
The reported investigation shows that the assessment of the possibility of the thermal fracture of brittle materials depends upon an accurate evaluation of the thermal stresses and the determination of the resulting stress intensity factors. The stress intensity factors can be calculated in a variety of ways ranging from the very precise to approximate, but only for a limited number of geometries. The main difficulty is related to the determination of the thermal stress field because of its unusual character and its dependence upon boundary conditions at points far from the region of thermal activity. Examination of a number of examples suggests that the best visualization of the thermal stresses and any associated fracture can be made by considering the problem to be the combination of thermal and isothermal problems or by considering that the prime effect of the temperature is in the generation of thermal strains and that the thermal stresses are simply the result of the region trying to accommodate these strains.
Emery, A. F.↗
High-intensity acoustic tests of a thermally stressed plate
An investigation was conducted in the Thermal Acoustic Fatigue Apparatus at the Langley Research Center to study the acoustically excited random motion of an aluminum plate which is buckled due to thermal stresses. The thermal buckling displacements were measured and compared with theory. The general trends of the changes in resonances frequencies and random responses of the plate agree with previous theoretical prediction and experimental results for a mechanically buckled plate.
Ng, Chung Fai↗
Thermal stress analysis of the NASA Dryden hypersonic wing test structure
Present interest in hypersonic vehicles has resulted in a renewed interest in thermal stress analysis of airframe structures. While there are numerous texts and papers on thermal stress analysis, practical examples and experience on light gage aircraft structures are fairly limited. A research program has been undertaken at General Dynamics to demonstrate the present state of the art, verify methods of analysis, gain experience in their use, and develop engineering judgement in thermal stress analysis. The approach for this project has been to conduct a series of analyses of this sample problem and compare analysis results with test data. This comparison will give an idea of how to use our present methods of thermal stress analysis, and how accurate we can expect them to be.
Morris, Glenn↗
Thermal stress fracture of ceramic coatings
Thermal stress failures of ceramic coatings are discussed in terms of fracture mechanics concepts. The effects of transient and residual stresses on single and multiple cycle failure mechanisms are considered. A specific example of a zirconia thermal barrier coating is presented and its endurance calculated using the proposed relationships.
Andersson, C. A.↗
[Presentation Slides] Code-to-Code Benchmark Study for Thermal Stress Modeling and Preliminary Analysis of the High-temperature Single Heat-Pipe Experiment
In the heat-pipe-cooled microreactor, heat pipes remove heat from the reactor core as a passive heat-transfer device, so the fluid circulation is not required for cooling, which can substantially simplify the overall reactor design. However, given the extremely high temperatures in the core region and potentially large temperature gradients across the structure materials, thermal stresses need to be well-analyzed to ensure structural integrity during normal operations and accident scenarios. This presentation slides discuss finite element method-based thermal-stress analysis for the high-temperature single heat-pipe test article in the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL), using two commercial software packages, Abaqus and Star-CCM+. A code-to-code benchmark study was performed to crosscheck the model setup and capability of each code and to gain preliminary insights into the potential thermal stress concerns from the current experimental setup. It is observed the significant thermal stresses happen at the inner surface of the heat pipe hole surrounded by electric heaters where the largest temperature gradients appear. The temperature fields have good agreements between Abaqus and Star-CCM+, while the induced thermal stresses show modest deviations probably due to differences of meshing engines used in these two codes. It is found that the local maximum thermal stresses may reach close to the ultimate tensile strength and yield strength of structural material depending on the heater power. Ultimately, the coupled thermal-structural analysis will help guide the current experimental plan and ensure the facility safety for future experimental study.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Accurate Thermal Stresses for Beams: Normal Stress
Formulations for a general theory of thermoelasticity to generate accurate thermal stresses for structural members of aeronautical vehicles were developed in 1954 by Boley. The formulation also provides three normal stresses and a shear stress along the entire length of the beam. The Poisson effect of the lateral and transverse normal stresses on a thermally loaded beam is taken into account in this theory by employing an Airy stress function. The Airy stress function enables the reduction of the three-dimensional thermal stress problem to a two-dimensional one. Numerical results from the general theory of thermoelasticity are compared to those obtained from strength of materials. It is concluded that the theory of thermoelasticity for prismatic beams proposed in this paper can be used instead of strength of materials when precise stress results are desired.
Johnson, Theodore F.↗
Accurate Thermal Stresses for Beams: Normal Stress
Formulations for a general theory of thermoelasticity to generate accurate thermal stresses for structural members of aeronautical vehicles were developed in 1954 by Boley. The formulation also provides three normal stresses and a shear stress along the entire length of the beam. The Poisson effect of the lateral and transverse normal stresses on a thermally loaded beam is taken into account in this theory by employing an Airy stress function. The Airy stress function enables the reduction of the three-dimensional thermal stress problem to a two-dimensional one. Numerical results from the general theory of thermoelasticity are compared to those obtained from strength of materials. It is concluded that the theory of thermoelasticity for prismatic beams proposed in this paper can be used instead of strength of materials when precise stress results are desired.
Johnson, Theodore F.↗
Transient thermal stress recovery for structural models
A method for computing transient thermal stress vectors from temperature vectors is described. The three step procedure involves the use of NASTRAN to generate an influence coefficient matrix which relates temperatures to stresses in the structural model. The transient thermal stresses are then recovered and sorted for maximum and minimum values. Verification data for the procedure is also provided.
Walls, William↗